Method for folding absorbent articles
The present invention is related to a method for folding an article into three parts comprising first folding a leading end portion of the article to form a first folded article, and second folding a trailing end portion of the first folded article, wherein the first folded article is transported with a moving direction change no higher than about 45 degree.
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The present invention relates to methods for folding absorbent articles. Specifically, the method can be used to fold absorbent articles into three parts in a longitudinal direction.
BACKGROUND OF THE INVENTIONAbsorbent articles such as sanitary napkins, adult incontinence articles, diapers and pantiliners are often manufactured and/or packaged on a high speed production line where individual articles may move along a production path at a speed of hundreds of meters per minute, for example higher than 200 m/min, and manufacturers of articles are continually trying to increase manufacturing speed.
During the manufacturing and/or packaging process, the absorbent article may undergo a folding process. One of ways to fold absorbent articles is a trifolding process by which an absorbent article is folded into three parts. A trifolding process may comprise folding absorbent articles about two fold lines which are transversal to their longitudinal axis, into three parts, respectively forming a leading portion, a central portion and a trailing portion of the article in a machine direction. In a trifolding process, an article may be first folded in around two thirds in the longitudinal direction by folding either the front portion or the rear portion, and second folded in around one third by folding the remaining rear portion or front portion. It is preferable that tri-folded pads has a consistent length among all the pads with minimum variation. However, current manufacturing practices often do not provide stable tri-folded product length for downstream pouch folding and packaging process, resulting in products that may have undesirable characteristics in the market place.
In a folding process providing a tri-folded article disclosed in Japanese laid-open patent publication No. 2002-18664, the folding process includes steps folding a trailing end portion first and then folding a leading end portion later. This type of process needs spacing between articles prior to first folding which requires accelerating moving speed of an article before the first folding. In addition, after tri-folding process, tri-folded product spacing needs to be reduced before moving into pouch folding process, which requires decelerating moving speed of an article. Such speed change tends to create increased article length variation which results in a wide variation in a tri-folded, article length which gets more conspicuous when process speed get faster.
In another folding process providing a tri-folded article disclosed in Japanese laid-open patent publication No. 2003/267468, the folding process includes steps of first folding a leading end portion, then turning the first folded article about 180 degree, and second folding a tailing end portion. This type of process may require a wide pad transition distance and product transition direction change between the first and the second folding steps which tends to increase article length variation. Product transition direction change between the first and second folding steps tends to increase article lenght variation. Japanese laid-open patent publication No. 2003/267468 discloses a folding equipment comprising a downward facing U-shape transport belt wrap around a guide drum which changes a moving direction of the first folded article about 180 degree.
Accordingly, there is a need for a process and a system for folding articles reducing tri-folded article length variation especially in high production speed.
In addition, there is a need for a process and a system for folding articles with minimizing an article transition distance and direction change between the first and second folding steps.
SUMMARY OF THE INVENTIONThe present invention is directed to a method for folding an article into three parts comprising first folding a leading end portion of the article to form a first folded article, and second folding a trailing end portion of the first folded article, wherein the first folded article is transported with a moving direction change no higher than about 45 degree.
The present invention is also directed to an apparatus for folding an article into three parts comprising a) a first pathway comprising convey system transporting the article, b) a first fold means for folding a leading end portion of the article, c) a second pathway comprising convey system transporting the article, d) a second fold means for folding a trailing end portion of the article, e) a third pathway comprising convey system transporting the article, wherein the second pathway has an angle T of moving direction change of the article not higher than about 45 degree, and wherein the first pathway and the third pathway are placed in the same side of the second pathway.
The term “absorbent article”, as used herein, includes disposable articles such as sanitary napkins, panty liners, diapers, adult incontinence articles, and the like. Such absorbent articles are intended for the absorption of body liquids, such as menses or blood, vaginal discharges, urine, and feces. Various absorbent articles described above will typically comprise a liquid permeable topsheet, a liquid impermeable backsheet joined to the topsheet, and an optional absorbent core between the topsheet and backsheet.
The term “body facing surface”, as used herein, refers to the side of the absorbent article facing the body of the user when in use, while the term “garment facing surface” as used herein refers to the outer or exterior surface of any article component that is intended to be worn or positioned adjacent a wearer's undergarments, or in the case of an absorbent article which is not worn by the user, the garment surface is typically positioned adjacent a user's hand or other implement assisting in the use of the absorbent article.
The term “comprising”, as used herein and in the claims, is inclusive or open-ended and does not exclude additional unrecited elements, compositional components, or method steps.
The term “engage,” as used herein, refers to the context of transferring an article from one pathway to another or from a portion of one pathway to another portion of the same pathway, means coming into close proximity (e.g., <10 cm, up to and including physical contact) such that an engaging force (e.g., suction) present at the surface of a carrier of the pathway can be applied to an article.
As used herein, a “fold line” is the portion of an article about which the article is folded. The fold line typically extends from one side edge to the opposing side edge in the crotch regions and, at least one of the leading portion edge and the trailing portion edge of an article may be aligned with one of fold lines when the article is folded.
The term “leading end portion”, as used herein, refers to a portion of an article that is forward of the first fold line in machine direction while the term “trailing end portion” refers to a portion of an article that is after the second fold line in the machine direction, and “central portion” refers to a portion connecting the leading end portion and the end trailing portion. The leading end portion and the trailing end portion do not necessarily means a front side portion and a rear side portion of an article respectively in terms of wearer's usage purposes.
The term “machine direction” or “MD”, as used herein, refers to the path that material, such as a web, follows through a manufacturing process, while the term “cross machine direction” or “CD” is the direction substantially perpendicular to the MD. Directions within 45 degrees of the cross direction are considered to be cross directional.
The term “trifold” or “trifolded”, as used herein, means folding an article having a leading end portion, a central portion, a trailing end portion, a first surface and a second surface opposite to the first surface into three portions. For example, trifolding an absorbent article may be accomplished by folding a leading end portion toward the first surface of a central portion of the article, and folding a trailing end portion toward the second surface of the leading end portion to cover at least a part of the second surface of the leading end portion as the article moves in the machine direction of travel, such that the article is folded along fold lines into three portions. In another example, trifolding an absorbent article may be accomplished by folding a leading end portion toward the first surface of a central portion of the article, and folding a trailing end portion toward the second surface of the leading end portion but not to cover the second surface of the leading end portion as the article moves in the machine direction of travel, such that the article is folded along fold lines into three portions.
For ease of understanding, portions of the following description may be exemplified in terms of an absorbent article. However, it is to be understood that while one or more particular examples recited herein may refer to a sanitary napkin, the present invention is not limited to such articles. The folding and transfer system described herein may, in fact, be practiced in any situation where an article exhibiting the characteristics described herein is required. Examples of other articles include hard surface cleaning wipes or pads; pre-moistened cloths; paper towels; dryer sheets and dry-cleaning clothes; adult incontinence briefs and undergarments; diapers; feminine hygiene garments such as panty liners, absorbent inserts, and the like; toilet paper; tissue paper; personal cleaning wipes or clothes such as baby wipes or facial wipes; packaging components and substrates and/or containers for laundry detergent and coffee, which may be produced in pellets or pouches and may be manufactured in a converting or web process; or even discrete products produced at high speed such as high-speed bottling lines, cosmetics, razor blade cartridges, and disposable consumer batteries.
Regarding all numerical ranges disclosed herein, it should be understood that every maximum numerical limitation given throughout this specification includes every lower numerical limitation, as if such lower numerical limitations were expressly written herein. In addition, every minimum numerical limitation given throughout this specification will include every higher numerical limitation, as if such higher numerical limitations were expressly written herein. Further, every numerical range given throughout this specification will include every narrower numerical range that falls within such broader numerical range and will also encompass each individual number within the numerical range, as if such narrower numerical ranges and individual numbers were all expressly written herein.
Absorbent Article
Absorbent articles folded by a method according to the present invention comprise a liquid pervious topsheet, a liquid impervious backsheet joined to the topsheet, and optionally an absorbent core located between the topsheet and the backsheet. The absorbent articles of the present invention may have a pair of flaps on longitudinal sides of a body-facing surface for folding around and securing the absorbent article to an undergarment.
An absorbent article may have a pair of flaps 60 on longitudinal sides of a body-facing surface for folding around and securing the absorbent article to the undergarment. When the absorbent article has a pair of flaps, the flaps are folded toward a longitudinal centerline of the article before a first folding according to the present invention as shown in
According to the methods and apparatuses disclosed herein, the article 100 may have fold lines dividing the absorbent article into three portions in the machine direction of travel, and be folded first about the first fold line 13 such that the leading end portion 15 and the center portion 16 are positioned in a face-to-face relationship along a body facing surface 50, and then folded about the second fold line 14 such that the body facing surface 50 of the trailing end portion 17 is positioned onto a garment facing area of the leading end portion 15.
A folded absorbent article according to certain embodiments may have the leading edge 11 and the second fold line 14 aligned and/or the trailing edge 12 and the first fold line 13 aligned.
In another example, according to the methods and apparatuses disclosed herein, the article 100 may have fold lines dividing the absorbent article into three portions in the machine direction of travel in a way that not all the three portions are in equal length, and be folded first about the first fold line 13 such that the leading end portion 15 and part of the center portion 16 are positioned in a face-to-face relationship along a body facing surface 50, and then folded about the second fold line 14 such that the trailing end portion 17 and part of the center portion 16 are positioned in a face-to-face relationship along a body facing surface 50.
A folded absorbent article produced according to the present invention preferably have a trifold configuration having an average MD length accuracy of ±6 mm, and an average CD width accuracy of ±3 mm when measured by a ruler.
Folding Process and Apparatus
As illustrated in
A second pathway 23 may comprises outer conveyor belt 231 on which one surface of first folded article 110 is placed and inner conveyor belt 232 disposed facing the other surface of the first folded article 110. The second pathway 23 transports the first folded article 110 toward second fold means 24 located near the end edge of the second pathway 23. The second pathway 23 may be substantially linear, bent or curved. When it is bent or curved, as shown in
A length P of the second pathway 23 is preferably no longer than about 3 meters, more preferably no longer than about 2 meters, even more preferably no longer than about 3 times a length of an article. If the length P of the second pathway 23 especially in a high speed process is too long, a length variation in MD in the article 100 tends to be bigger. In addition, if P of the second pathway 23 is longer than about 3 meters, convey belt tension and CD tracking may be difficult to control and conveyor belt slip and CD tracking deviation may be amplified, which will cause defects in folded products and packaging quality defect. A length P of the second pathway 23 is preferably not shorter than the same as a length of the article 100. If the length P is too short, an article is second folded before a first folding of an article is completed which may create an unstable positioning of an article during article transition.
The length P of about 1.5-about 3 times length of article 100 is preferably. When the second pathway 23 is not continuous and consists of multiple conveyor systems comprising a conveyor belt and roller system, a length P of the second pathway 23 is understood a total of a length of each conveyor belt and a space between two consecutive conveyor belts.
When the second pathway 23 is not continuous and consists of multiple conveyor systems comprising a conveyor belt and roller system, a length P of the second pathway 23 is understood a total of a length of each conveyor belt and space between two consecutive conveyor belts.
As illustrated in
In one embodiment, the inner conveyor belts 212, 232 and 252 are connected and continuous. In one embodiment, the first pathway 21 and the third pathway 25 are disposed in the same side about the second pathway 23 as shown in
First fold means 22 is located in a finishing end side of the first pathway in a machine direction and second fold means 24 is located in a finishing end side of the second pathway in a machine direction. First fold means 22 is located between the first pathway 21 and the second pathway 23, so that when the leading end portion of the article 100 projects from the end edge of the first pathway 21, the first fold means 22 folds the article 100 along a first fold line and further causes the first folded article 110 to be delivered to the second pathway 23.
Second fold means 24 is located between the second pathway 23 and the third pathway 25, so that when the first folded article 110 projects from the end edge of the second pathway 23, the second fold means 24 folds the first folded article 110 delivered from the second pathway 23 along a second fold line and further causes the second folded article 120 to be delivered to the third pathway 25.
In further embodiments, the second folded articles 120 may travel along another pathway or be subjected to further processing, such as wrapping, stacking, packaging, etc.
The process according to the present invention can reduce folded pad length variation, avoid skewed folding, prevent tri-folded article 120 in crimp attribute defect, stabilize following transition process between article fabrication machines and a packaging machine, and enhancing bag tightness and appearance.
Fold means suitable for the folding apparatus in accordance with the present invention may be a pair of tuckers rotating in opposite directions. In an embodiment of a folding apparatus 5 as shown in
As can be seen in
“Clearance A1” refers to the shortest distance between a surface of the inner conveyor belt 232 of the second pathway 23 towards the outer conveyor belt 231 and a top surface 310 of a blade of the first tucker when the blade is engaged with the article 100. A1 may be in the range of from about 50% to about 150% of a thickness of the article 100. “Clearance A2” refers to the shortest distance between a surface of the outer conveyor belt 231 of the second pathway 23 towards the inner conveyor belt 232 and a bottom surface 320 of a blade of the first tucker when the blade is engaged with the article 100. A2 may be in the range of from about 20% to about 150% of a thickness of the article 100. Clearance A1 and A2 in a preferable range may avoid tearing of a topsheet and crimp attribute defect of an absorbent article, and secure consistent length of tri-folded articles.
As can be seen in
Other suitable forms of fold means also may be appropriate for use with some embodiments of selective fold means of the present disclosure. It is further recognized that the terms tucker, or tucker blade may refer to any suitable mechanism for engaging the articles 100 or the first folded article 110 and causing the articles 100 or the first folded article 110 to be folded about a folding line—typically, though not exclusively, an imaginary line—that defines two or more generally symmetrical or asymmetrical portions the articles 100 or the first folded article 110. Furthermore, tucker blades 29 may be manufactured from any suitable materials such as, but not limited to, metal, metallic alloys, plastics, etc., or combinations thereof.
As shown in
Yet another embodiment of fold means for the present invention can be seen in
Other suitable forms of fold means also may be appropriate for use with some embodiments of selective folding apparatus of the present disclosure. It is further recognized that the terms tucker, tucker blade, or tucker arm may refer to any suitable mechanism for engaging an article and causing the article to be folded about an axis—typically, though not exclusively, an imaginary line—that defines two or more generally symmetrical or asymmetrical portions of the article. Furthermore, tucker blades 29 and 32 and tucker arm 51 may be manufactured from any suitable materials such as, but not limited to, metal, metallic alloys, plastics, etc., or combinations thereof.
Fold means may comprise any drive mechanism 74 for operating a tucker blade. In an embodiment of fold means, illustrated in
In an embodiment, main shaft 61 may directly drive the fold means. In a further embodiment, main shaft 61 may indirectly drive the fold means. For example, in an embodiment, the main shaft 61 may be linked to phasing gear box 62, which may phase the driving rotation of main shaft 61 to engage fold means with passing an article. A line shaft drive mechanism may further include disengagement clutch 64. Disengagement clutch 64 may cause fold means to slow down, stop, and/or restart during operation of a folding apparatus. That is, at any suitable moment, disengagement clutch 64 may cause drive mechanism 74 to slow down or stop, which may further prevent fold means from engaging, folding, and/or delivering an article. In other embodiments, disengagement clutch 64 may be replaced by other suitable mechanisms for slowing or stopping fold means from engaging or folding an article, or delivering an article to a next pathway. Linking belt 68 may link main shaft 61, phasing gear box 62, or disengagement clutch 64 with tucker blades 29 or 32 or tucker arm 51. In an embodiment, linking belt 68 may be a belt or chain. In alternative embodiments, linking belt 68 may be any suitable means for connecting main shaft 61, phasing gear box 62, or disengagement clutch 64 with tucker blades 29 or 32 or tucker arm 51, such that drive mechanism 74 is linked to tucker blades 29 or 32 or tucker arm 51, such as via gears or gearboxes.
In another embodiment, illustrated in
In yet a further embodiment, shown in
Although fold means illustrated in
The dimensions and values disclosed herein are not to be understood as being strictly limited to the exact numerical values recited. Instead, unless otherwise specified, each such dimension is intended to mean both the recited value and a functionally equivalent range surrounding that value. For example, a dimension disclosed as “40 mm” is intended to mean “about 40 mm”.
Every document cited herein, including any cross referenced or related patent or application, is hereby incorporated herein by reference in its entirety unless expressly excluded or otherwise limited. The citation of any document is not an admission that it is prior art with respect to any invention disclosed or claimed herein or that it alone, or in any combination with any other reference or references, teaches, suggests or discloses any such invention. Further, to the extent that any meaning or definition of a term in this document conflicts with any meaning or definition of the same term in a document incorporated by reference, the meaning or definition assigned to that term in this document shall govern.
While particular embodiments of the present invention have been illustrated and described, it would be obvious to those skilled in the art that various other changes and modifications can be made without departing from the spirit and scope of the invention. It is therefore intended to cover in the appended claims all such changes and modifications that are within the scope of this invention.
Claims
1. A method for folding an article along a transversal first fold line and a transversal second fold line of the article, the article having a leading end portion, a trailing end portion, and a central portion connecting the leading end portion and the trailing end portion in a longitudinal direction, the method comprising:
- a) transporting the article to a first fold means by a first pathway comprising a first convery system,
- b) folding the leading end portion of the article transported by the first pathway along the first fold line to form a first folded article and delivering the first folded article to a second pathway comprising a second convey system by the first fold means,
- c) transporting the first folded article to a second fold means by the second pathway,
- d) folding the trailing end portion of the first folded article along the second fold line to form a second folded article and delivering the second folded article to a third pathway comprising a third convey system by the second fold means, and
- e) transporting the second folded article by the third pathway, wherein the first fold means is located in a finishing end side of the first pathway in a machine direction and the second fold means is located in a finishing end side of the second pathway in the machine direction, wherein the first folded article is transported with an angle of moving direction change no higher than 45 degrees, wherein the second pathway has a length that and the article has a length, and wherein the length of the second length is greater than or equal to the length of the article but no longer than 3 meters.
2. The method for folding an article according to claim 1, wherein the second pathway is linear.
3. The method for folding an article according to claim 1, wherein at least one of the first fold means and the second fold means is a folding means having a tucker blade.
4. The method for folding an article according to claim 3, wherein the folding means is a dual propeller-style tucker.
5. The method for folding an article according to claim 1, wherein the first fold line and the second fold line divide the article into three portions in the machine direction.
6. The method for folding an article according to claim 1, wherein the first fold line and the second fold line divide the article into three portions in a way that at least two of the three portions have different lengths in the machine direction.
7. The method for folding an article according to claim 1, wherein the article is an absorbent article.
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Type: Grant
Filed: Jun 11, 2015
Date of Patent: Jul 10, 2018
Patent Publication Number: 20150374555
Assignee: The Procter & Gamble Company (Cincinnati, OH)
Inventors: Ran Chen (Guangzhou), Yize Fang (Hangzhou)
Primary Examiner: Hemant M Desai
Assistant Examiner: Tanzim Imam
Application Number: 14/736,355
International Classification: A61F 13/15 (20060101); B65H 45/04 (20060101);
